US8081413B2 - Intrinsically safe ethernet-based communication - Google Patents

Intrinsically safe ethernet-based communication Download PDF

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Publication number
US8081413B2
US8081413B2 US11/568,567 US56856705A US8081413B2 US 8081413 B2 US8081413 B2 US 8081413B2 US 56856705 A US56856705 A US 56856705A US 8081413 B2 US8081413 B2 US 8081413B2
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parallel diode
diode pair
anti parallel
intrinsically safe
fuse
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US20080285186A1 (en
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Ajay Kothari
Naresh Molleti
Parag Shah
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Eaton Intelligent Power Ltd
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Azonix Corp
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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02H—EMERGENCY PROTECTIVE CIRCUIT ARRANGEMENTS
    • H02H9/00—Emergency protective circuit arrangements for limiting excess current or voltage without disconnection
    • H02H9/008—Intrinsically safe circuits
    • H—ELECTRICITY
    • H04—ELECTRIC COMMUNICATION TECHNIQUE
    • H04L—TRANSMISSION OF DIGITAL INFORMATION, e.g. TELEGRAPHIC COMMUNICATION
    • H04L12/00—Data switching networks
    • H04L12/02—Details
    • H04L12/10—Current supply arrangements

Definitions

  • the present invention relates generally to the field of communications in hazardous area. More specifically, the present invention is related to cost-effective intrinsically safe Ethernet-based communications based on IEEE 802.3/u,z/ab/ae.
  • Ethernet has become a standard choice for digital communication between various pieces of communication hardware.
  • One known prior art solution involves the use of a specialized copper cable and connector combination.
  • Another prior art solution involves using fiber optic cables.
  • Both of the above-mentioned prior art solutions suffer from many drawbacks, one of which is the cost of implementing such solutions.
  • Both the above-mentioned prior art solutions are expensive and severely limit the ease of use and maintenance in the field.
  • the fiber does not have any electrical energy hence are easily acceptable in hazardous area.
  • the fiber cables are delicate hence easy to break and very difficult to repair in the field. In many industrial applications the fiber cables require special jacket because of environmental conditions and this makes them expensive.
  • the fiber connectors are not necessary. But in the application where equipments are frequently moved, the connectors are desired. These connectors are expensive and are prone to malfunction due to dust, and are, hence, difficult to maintain.
  • I.S. Ethernet Since the fiber optic solution is cost-prohibitive and the non-I.S. copper cable and connector solution is not ideal, there is a need for an inexpensive I.S. Ethernet solution.
  • Some of the major benefits of I.S. Ethernet are: (1) industry standard (2) use of standard cable and connector that is widely available at a very cheap cost because the design is I.S. and (3) ability to hot-plug the network. This would reduce that operating cost in the field dramatically and make it user friendly for installation, maintenance, etc.
  • the serial link is a common method of communication in industrial automation world. There are several advantages of using the serial communication. Some of these are: ease of implementation, lower cost of cabling, very common, hence, ease of finding the alternate and compatible devices etc. Some of the major benefits in the Hazardous area are (1) the ability to make the design Intrinsically Safe due to reduced number of channels (as compared to parallel devices), and (2) the lower cost of implementation for devices, cables and installation.
  • Ethernet provides users an industrial network that has a lower cost of ownership with improved adaptability for their changing business needs. This, combined with widespread availability and market familiarity, continues to drive Ethernet's use in industrial automation applications for a broad range of industries. Now the Ethernet is widely offered in PLCs as well as devices.
  • the I.S designs are low voltage, low current and has limited power, capacitance and inductance such that even in fault conditions the energy is not sufficient to cause an explosion.
  • I.S. Ethernet One of the inherent problem in I.S. design is the speed as the I.S. design requires putting fuse, Zeners (or diodes) and resistor to limit the voltage and current under fault conditions. These components act like Resistor-Capacitor circuit that distorts frequency characterization of the high speed signals preventing high-speed communication.
  • Kessler et al. U.S. Pat. No. 6,154,683
  • Rockwell Technologies, LLC provides for a Low Voltage Industrial Control System Providing Intrinsically Safe Operation.
  • Hazardous area 20 is provided with intrinsically safe I/O rack 24 ′, including communications module 30 ′, which provides high speed serial data communication between control points 36 in the hazardous area and control terminal 22 located outside of the hazardous area over serial link 28 ′ through penetration circuit 34 to serial link 28 located outside of the hazardous area.
  • Kessler et al. mention the use of a high-speed serial bus and fails to address bandwidth limitations.
  • the general purpose serial link in the industrial control world has a different meaning than Ethernet. Ethernet is not viewed as a serial link due to tight timing requirements.
  • the patent application publication to Vazach et al. (2005/0024160 A1) provides for an In-Line Passive Barrier for Intrinsically Safe Communication Network.
  • Network barrier 20 is mounted on DIN rail 21 along with communication module 16 of a standard high speed serial network 18 , such as Ethernet, and the two are connected by cabling.
  • the barrier is also connected by cabling to network card 16 ′ of intrinsically safe rack 12 ′ located in hazardous area 17 .
  • the intrinsically safe rack includes I/O modules 14 that communicate with controlled equipment 22 located in the hazardous area (see paragraphs 44-46).
  • the barrier mentioned here is for co-axial cable for high-speed serial communication.
  • the invention here is based on standard ethernet communication with twisted pair cables (ex. CAT5, CAT5e, CAT6) cable using standard RJ145 connector.
  • the patent to Lewis et al. (U.S. Pat. No. 5,712,631), assigned to Halliburton Company, provides for an Intrinsically Safe Data Network.
  • a boundary crossing connector which includes one or more intrinsic safety barriers, that connects a communication interface means located inside a hazardous zone to external processing means.
  • the Data Network corresponds to an RS-485 interface (not Ethernet), the implementation is of which is very different than Ethernet.
  • the present invention provides for a computer-based system with an intrinsically safe barrier for use in a hazardous area comprising: (a) a fuse receiving an unsafe signal from a first network device; (b) a voltage clamping device comprising a plurality of back-to-back diodes; (c) a current limiting resistance, wherein a value of the current limiting resistance depends on a clamping voltage value associated with the voltage clamping device.
  • the intrinsically safe barrier clamps input voltage and limits short circuit current to provide an intrinsically safe signal as an output to a second network device.
  • the present invention also provides for an intrinsically safe network switch for use in a hazardous area comprising: (a) a power input; (b) an input port to receive an unsafe network input signal, wherein the input port works in conjunction with a first intrinsically safe barrier; (c) at least one output port to transmit a safe network output signal, wherein the output port works in conjunction with a second intrinsically safe barrier.
  • each of the first and second intrinsically safe barriers further comprises a fuse, a voltage clamping device comprising a plurality of back-to-back diodes, and a current limiting resistance.
  • a value of the current limiting resistance depends on a clamping voltage value associated with the voltage clamping device, and the first and second intrinsically safe barriers clamp input voltage and limit short circuit current to provide an intrinsically safe output signal.
  • the present invention also provides for an intrinsically safe network switch for use in a hazardous area, wherein the network-based switch is used to provide both an intrinsically safe data signal and an intrinsically safe power signal.
  • the intrinsically safe network switch according to this embodiment comprises: (a) a power input working in conjunction with a first intrinsically safe barrier; (b) an input port to receive an unsafe network input signal, wherein the input port works in conjunction with a second intrinsically safe barrier; and (c) at least one output port to transmit a safe network output signal, wherein the output port works in conjunction with a third intrinsically safe barrier, each of said first, second, and third intrinsically safe barriers further comprising a fuse, a voltage clamping device comprising a plurality of back-to-back diodes, and a current limiting resistance.
  • a value of the current limiting resistance depends on a clamping voltage value associated with the voltage clamping device, and the first, second, and third intrinsically safe barriers clamp input voltage and limit short circuit current to provide an intrinsically safe output signal.
  • the present invention also provides for an intrinsically safe barrier protecting an integrated circuit in a hazardous area, wherein the integrated circuit performs network-based communications and the intrinsically safe barrier comprises: (a) a fuse receiving an unsafe signal from the integrated circuit; (b) a voltage clamping device comprising a plurality of back-to-back diodes; (c) a current limiting resistance, wherein a value of the current limiting resistance depends on a clamping voltage value associated with the voltage clamping device.
  • the intrinsically safe barrier when used in conjunction with the integrated circuit, clamps input voltage and limits short circuit current to provide an intrinsically safe integrated circuit output signal.
  • FIG. 1 illustrates a network switch according to the present invention.
  • FIG. 2 illustrates another view of the Ethernet switch used in accordance with the teachings of the present invention.
  • FIG. 3 illustrates such a prior art scenario using Zener diodes.
  • FIG. 4 illustrates the present invention's implementation of back-to-back diodes.
  • FIG. 5 illustrates an electrical schematic describing I.S. Barrier for “Unsafe” signals coming from PC/Controller Ethernet I/O.
  • FIG. 6 illustrates an electrical schematic describing I.S. barrier for signals going into a hazardous area.
  • the present invention provides for a system and method implementing Intrinsically Safe (IS) Ethernet based on the IEEE standard, wherein the system and method can be used in Hazardous area to attain a high-bandwidth (e.g., 10 MBPS, 100 MBPS or greater) connection using standard CAT5, 5e or 6 cable and standard RJ45 connector. Additionally, a live disconnect of the ports can be performed, if needed, in a hazardous area.
  • IS Intrinsically Safe
  • the present invention also provides for a system and method that provides intrinsically safe Power over Ethernet (PoE) for the use in a hazardous area, wherein a single standard Ethernet cable is used for both communication and power in Hazardous area.
  • PoE Power over Ethernet
  • FIG. 1 illustrates an Ethernet switch 100 according to the present invention.
  • the Ethernet switch comprises an input D.C. power 102 , an input port 104 for receiving an input such as a CAT5 networking cable, and one or more output ports 106 - 1 through 106 - 4 .
  • FIG. 2 illustrates another view of the Ethernet switch used in accordance with the teachings of the present invention.
  • FIG. 2 illustrates an intrinsically safe network switch 200 for use in a hazardous area, wherein the network-based switch is used to provide both an intrinsically safe data signal and an intrinsically safe power signal.
  • the intrinsically safe network switch comprises: (a) block 202 representing a power input working in conjunction with a first intrinsically safe barrier to provide an intrinsically safe power output; (b) block 204 representing an input port to receive an unsafe network input signal, wherein the input port works in conjunction with a second intrinsically safe barrier; and (c) blocks 206 - 1 through 206 - 4 representing one or more output ports to transmit a safe network output signal, wherein the output port works in conjunction with a third intrinsically safe barrier, each of said first, second, and third intrinsically safe barriers further comprising a fuse, a voltage clamping device comprising a plurality of back-to-back diodes, and a current limiting resistance.
  • a value of the current limiting resistance depends on a clamping voltage value associated with the voltage clamping device, and the first, second, and third intrinsically safe barriers clamp input voltage and limit short circuit current to provide an intrinsically safe output signal.
  • the present invention's system and method uses back-to-back diodes (instead of Zener diodes).
  • the use of back-to-back diodes provide better control over forward voltage conduction as compared to Zeners for which the V-I characteristic knee is poor for voltages below 4.7V.
  • FIG. 3 illustrates such a prior art scenario using Zener diodes.
  • One disadvantage associated with circuits implementing Zener diodes is that when such circuits operate at a lower voltage (i.e., below 4.7V), the Zener diodes conduct (i.e., allows the current to flow through them), a limitation that is not desirable.
  • the forward (and reverse) voltage can be better controlled as the typical diode start conducting at 0.7V.
  • more diodes are required to make sure the diode channel does not conduct in normal operation.
  • the output resistance value is derived from the clamping voltage—the higher the voltage, the higher the resistance value. Hence, by lowering the clamping voltage, the output resistance can be lowered (which is desired for high frequency signals).
  • the power in the voltage clamping devices are calculated as following:
  • the parasitic capacitance With larger diode packages (including Zener diodes), due to the silicon junction characteristics, the parasitic capacitance is high. Similarly, with the use of smaller diodes, the parasitic capacitance is low.
  • the parasitic capacitance in the voltage clamping devices, along with fuse resistance and current limit resistance significantly changes the spectral response of the Ethernet channel thereby severely band-limiting the transmission channel. This is not good for high speed Ethernet signals as it causes Inter symbol Interference (ISI) and subsequently creating a lot of bit errors.
  • ISI Inter symbol Interference
  • back-to-back diodes are used.
  • redundant channels of voltage clamping circuitry is required.
  • the parasitic capacitors add up when connected in parallel but there are more numbers of diodes in each line to get to the desired voltage (e.g., assuming diode forward voltage ⁇ 0.7V and voltage clamp is desired at 4.9V, 7 such diodes are required.) Adding these diodes in series puts the parasitic capacitance in series hence the total capacitance drops. Therefore, adding more diodes in series offer the same parasitic capacitance as the diodes in 1 channel (including redundancy).
  • FIG. 5 illustrates an electrical schematic describing I.S. Barrier for “Unsafe” signals coming from PC/Controller Ethernet I/O.
  • the use of a fuse, a voltage clamping device, and a resistor is in accordance with the I.S. standard.
  • the use of diodes as a voltage clamping device offers advantages as described in earlier section.
  • Use of “blocking capacitors” offers high voltage isolation necessary for operation in industrial applications. The isolation obtained by this method is 1500V RMS. However, it should be noted that the isolation voltage can be increased or decreased based on the capacitor selection, and hence should not be used to limit the scope of the invention.
  • the use of blocking capacitor also offers an excellent protection to the fuse in case or erroneous shorts that occurs in regular day-to-day operation. Without such protection, the device could fail frequently and lower the system reliability.
  • FIG. 6 illustrates an electrical schematic describing I.S. Barrier for signals going into a hazardous area.
  • the present invention's teachings can be used to increase or reduce the total number of ports available, without departing from the scope of the present invention.
  • the Ethernet I/O signals interface to an Ethernet integrated circuit (I.C.).
  • I.C. can be any standard I.C. capable of doing the desired operation.
  • the IC can be a “managed” switch or an “unmanaged” switch.
  • the selection of ‘R’ is based on the I.S. standards and is derived from the selection of voltage clamping circuit.
  • the fuse used here is to limit the power rating of the “R”.
  • the power rating of “R” can be derived from 2 possible ways.
  • the Ethernet I.C. can be replaced with any other LC. that is required for high bandwidth (high frequency) communication (e.g., greater than or equal to 10 MBPS).
  • the I.C. is an “unmanaged” switch, and in another embodiment, the basic I.C. can be replaced to create a “managed” switch.
  • the current design shows the design of 4-port Ethernet switch. This design increases complication as well as cost. It should be noted that the teachings of the present invention can be used to implement an application that requires only a single channel using the “Unsafe Ethernet I/O” barrier circuitry.
  • the blocking capacitors used in the design offer good isolation (and impedance) at the lower frequency (such as 50/60 Hz) that is more common in the plants/installations. These capacitors offer very low impedance at the operating frequency and, hence, are not sufficient to limit the I.S. current. This forces the use of current limiting “R” in the design. With the selection of better capacitors that offer adequate “R” at the operating frequency, it is possible to eliminate the current limiting “R”. However, this requires extensive testing to prove that these are sufficient to restrict the short circuit current as per I.S. standards.
  • block 204 represents the I.S. barrier for the signal from non I.S. (unsafe) signal I/P from OC/Controller ethernet devices.
  • the block 204 is designed as described in FIG. 5 .
  • the block 204 can be replaced by galvanic isolation created using optical methods (such as back-to-back copper-to-fiber & fiber-to-copper converter preventing any electrical energy entering the device from unsafe area) or by transformer isolation. These concepts were considered during the design concepts but were not implemented as it would increase the cost of the final product.
  • teachings of the present invention can be combined to provide an intrinsically safe solution to transfer power as well as signal on the same cable (i.e., Power over Ethernet or PoE based on IEEE 802.3af).
  • Power-over-Ethernet technology allows network switches, wireless LAN Access Points and other appliances to receive power as well as data over existing LAN cabling, without needing to modify the existing Ethernet infrastructure.

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  • Emergency Protection Circuit Devices (AREA)
  • Cable Transmission Systems, Equalization Of Radio And Reduction Of Echo (AREA)
  • Control Of Driving Devices And Active Controlling Of Vehicle (AREA)
  • Near-Field Transmission Systems (AREA)
  • Compositions Of Oxide Ceramics (AREA)
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PCT/US2005/035877 WO2007040539A1 (fr) 2005-10-05 2005-10-05 Communication ethernet à sécurité intrinsèque

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US20110182064A1 (en) * 2009-02-26 2011-07-28 Ghulam Hasnain Light Sources Utilizing Segmented LEDs to Compensate for Manufacturing Variations in the Light Output of Individual Segmented LEDs
US20160146924A1 (en) * 2014-11-26 2016-05-26 Honeywell International Inc. Intrinsic safety barrier circuit with series blocking capacitor
US9778149B2 (en) 2014-05-02 2017-10-03 Swagelok Company Fluid sample system and method
US10905025B1 (en) * 2019-06-12 2021-01-26 Facebook, Inc. Interconnection module and server rack

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EP1982397B1 (fr) * 2006-01-24 2019-07-10 Fisher Controls International Llc Appareil ignifuge utilisant une barriere de limitation d'energie non mise a la terre
WO2010133287A2 (fr) 2009-05-20 2010-11-25 Aktiebolaget Skf Composant de traitement de données générique, certifié pour tâche critique
EP2433187B1 (fr) * 2009-05-20 2020-08-19 Aktiebolaget SKF Composant de traitement de données générique, certifié pour tâche critique
DE102009029307A1 (de) * 2009-09-09 2011-03-10 Endress + Hauser Wetzer Gmbh + Co Kg Vorrichtung zur Übertragung eines Steuersignals
DE202010000110U1 (de) * 2010-02-01 2011-06-01 Bucyrus Europe GmbH, 44534 Eigensichere Anschlusseinheit mit Netzwerk-Schnittstelle, eigensicheres Gerät und Netzwerk-Schnittstelle hierfür
DE102010063437A1 (de) * 2010-12-17 2012-06-21 Siemens Aktiengesellschaft Verfahren zur Konfiguration eines oder mehrerer Geräte in einem Ethernet-basierten Kommunikationsnetz
DE102011003978B4 (de) * 2011-02-11 2020-06-04 Ecom Instruments Gmbh Schaltungsanordnung zur Leitungssicherung und Modul, das dieselbe enthält
US8732489B2 (en) * 2011-09-07 2014-05-20 General Electric Company Communication system for use in hazardous environments
DE102013103627A1 (de) * 2013-04-11 2014-10-16 Endress + Hauser Flowtec Ag Feldgerät mit einer Schutzschaltung
US10027067B2 (en) * 2013-07-26 2018-07-17 Solexy Usa, Llc Hazardous area coupler device for high frequency signals
EP4381577A1 (fr) * 2021-08-04 2024-06-12 Abb Schweiz Ag Circuit à sécurité intrinsèque pour charge

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US20110182064A1 (en) * 2009-02-26 2011-07-28 Ghulam Hasnain Light Sources Utilizing Segmented LEDs to Compensate for Manufacturing Variations in the Light Output of Individual Segmented LEDs
US9472593B2 (en) * 2009-02-26 2016-10-18 Bridgelux, Inc. Light sources utilizing segmented LEDs to compensate for manufacturing variations in the light output of individual segmented LEDs
US9634062B2 (en) 2009-02-26 2017-04-25 Bridgelux, Inc. Light sources utilizing segmented LEDs to compensate for manufacturing variations in the light output of individual segmented LEDs
US9913333B2 (en) 2009-02-26 2018-03-06 Bridgelux Inc. Light sources utilizing segmented LEDs to compensate for manufacturing variations in the light output of individual segmented LEDs
US10334674B2 (en) 2009-02-26 2019-06-25 Bridgelux Inc. Light sources utilizing segmented LEDs to compensate for manufacturing variations in the light output of individual segmented LEDs
US10966300B2 (en) 2009-02-26 2021-03-30 Bridgelux, Inc. Light sources utilizing segmented LEDs to compensate for manufacturing variations in the light output of individual segmented LEDs
US9778149B2 (en) 2014-05-02 2017-10-03 Swagelok Company Fluid sample system and method
US20160146924A1 (en) * 2014-11-26 2016-05-26 Honeywell International Inc. Intrinsic safety barrier circuit with series blocking capacitor
US10905025B1 (en) * 2019-06-12 2021-01-26 Facebook, Inc. Interconnection module and server rack

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WO2007040539A1 (fr) 2007-04-12
ATE463010T1 (de) 2010-04-15
DE602005020370D1 (de) 2010-05-12
EP1932078B1 (fr) 2010-03-31
EP1932078A1 (fr) 2008-06-18
US20080285186A1 (en) 2008-11-20

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